Periodically, I build Colonial-style kitchen cabinets with flush-mounted doors. One kitchen can have at least 20 or so doors with relatively small butt hinges mortised into the edge of each door. To cut the hinge mortises, I use a router and a simple jig made from scrap. It consists of two arms spaced apart by a block the same thickness as the door frame. This spacer block also serves as a stop block in positioning the jig on the doors. I attach two 1/2-in. plywood fences to the top of the arms. The distance between the fences determines the size of the hinge mortises. Calculate this distance by adding the base of the router plus the width of the hinge minus the width of the mortising bit. Secure the jig to the door with a spring clamp.

To use the jig, put a door in the bench vise. Place the jig on the door with the stop block placed snugly against one end, and clamp it in place with the spring clamp. Set your router to a depth slightly less than the thickness of the hinge.

Reduce tearout by cutting the first and second passes, as shown in the drawing, and then clean out the remainder in the middle. Reverse the door in the vise, clamp the jig to the other end and cut the second mortise.

This jig is so easy to build that I don’t bother to make it adjustable. I just keep one on hand for each size hinge I use.

Jeff Lind, South Berwick, Maine

Fine Woodworking Magazine, December 1996 No. 121

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